Electrical connector



Sept. 28, 1948. J, c. c I 2,450,202

ELECTRICAL cbauEc'roa Filed Oct. 27, 1944 2 Shee ts-Sheot 1 INVENTOR James'a Macy at ATTORN vs J. C. M'ACY ELECTRICAL CONNECTOR Sept. 28, 1948.

2 Sheets-Sheet 2 Filed Oct. 27, 1944 I INVENTOR 65 James 6'- Ma Patented Sept. 28, 1948 UNITED STATES PATENT OFFICE cameraman oomc'ron James C. Macy, New Cumberland Pm, assignor to Aircraft-Marine Products Inc., Harrisburg, Pa., a. corporation of New Jersey Application mm 27, 1944, Serial No. 560,606

12 Claims. 1

This invention relates to interconnectors and connector blocks of the type which permit a good electrically conductive, readily disconnectible interconnection to be made between two or more electrical conductors. The invention relates particularly to interconnectors and connector blocks for use with terminal connectors of the knife disconnect type, c. g. as described and claimed in my copending application, Serial No. 530,317, filed April 10, 1944.

It is frequently desirable in wiring systems to plying the invention to practical use and thus to so fully instruct others skilled in this art that bring wires from various circuit elements "to a convenient location where interconnections are made on a terminal block or panel. In this 'way installation, testing and replacement of circuits is facilitated. As a consequence of this practice there has grown up a demand for such interconnecting terminal blocks which are compact, well ,to provide an interconnector which is compact,

occupying a minimum of space, but in which the connections are readily accessible. Another obiect is to provide an interconnector block in which all conducting parts are insulated from accidental contact while in normal use. Another object of the invention is to provide a standard intercon- -nector block of relatively long lengths convenient for shipping and stocking from which convenient lengths with required number of connections can be cut at will and in which desired connectors can be electrically connected while others remain electrically isolated. Other objects and advantages will be apparent from the following specification and claims and the accompanying drawings.

Although in this specification and the accompanying drawings I am showing and describing a particular example and various modifications thereof, it should be understood that these are not intended to be exhaustive or limiting of the invention, but on the contrary are chosen and presented for purposes of illustration and in order to explain the principles of the invention and the practical employment of those principles in apthey will be enabled readily to modify and to select and substitute alternatives, each as may be best suited to the particular conditions of any given application or use.

In the drawings:

Figure 1 is a perspective view of an interconnector block with circuit Wires leading into it and its cover locked in. place as in normal use;

Figure 2 is a fragmentary plan view of one end of the block shown in Figure 1 withthe cover removed, and the wire connections removed from one 01' the interconnector'unlts;

Figure 3 is an and elevation 01 one of the interconnector units emloyed in the connector block;

Figure 4 shows a blank from which the integral interconnector shown in Figure 3 may be formed;

Figure 5 shows, partly in plan view and partly in longitudinal section, a modified interconnector unit suitable for use in a connector block such as that shown in Figures 1 and 2, but shown connected to two wires with a simple tubular insulating sheath;

Figure 6 shows,in plan view, a further modification of the interconnector unit;

Figure 7 is a view in side elevation of the inter-. connector of Figure 6;

Figure 8 is a fragmentary perspective view of one end of a connector block similar to that of Figure 1, but somewhat modified;

Figure 9 is a perspective view from the opposite side of the end fitting shown in Figure 8;

Figure 10 is a plan view of the'blank from which the end fitting of Figure 9 is made; and

Figure 11 is a view in vertical section taken on line l|-|l of Figure 8.

In the embodiment of the invention shown in Figures 1 to 4. the connector block comprises a molded block of insulation 2, having therein transverse channels 4 each shapedto receive a novel two-way interconnector 5 of the present invention and having longitudinal channels 6 connecting, successive transverse channels 4, these longitudinal channels 6 being adapted to receive, in overlapping relation, the integral contact lugs 1 extending laterally from the clips in of any two essence filed April it, 194%. This inter-connector comprises two oppositely extending blade members a obliquely oiiset irom each other so that they lie in spaced parallel planes. integrally extending from the bottom of each blade at a distance from its end is a clip to adapted to receive the blade 52 of a knife-disconnect terminal connector, which on its part receives the blade 8 of the interconnector between its blade l2 and its clip it.

The block 2 is formed with a cavity is in the bottom of each of diagonally opposite corners or each channel ii under the freely extending blade portions it. The depth of this cavity as well as the spacing of the blade portion 3 xrom the adjacent wall it is such as to facilitate positioning of the clip it under the blade when the terminal connector is pushed vertically to the bottom or the cavity, it with lateral pressure against the wall it. Thus the clip it is properly positioned; and when it is swung down into position parallel with the blade b, the clip engages the blade as shown.

The well ill of the cavity serves as an abutment I for the end of the terminal H to assure itsiassuming proper longitudinal relation to the blade 8 and the clip it.

The two way connector shown in Figures 1 to 3 can be formed from a single sheet metal stamping of which the flat blank outline is shown in Figure 4. Referring to this figure, it will be seen that the blank comprises the blade portions 8, a connecting saddle portion 56 and the clip parts in which are bent over the blades 8. to form the clips as shown in Figures 1 to 3. The oblique connecting body portion 35 is bent into U-sh'ape to form a saddle portion, as shown in Figure 2. This automatically brings the blades 8 into parallel planes and into obliquely oflset relation to each other. its also shown in Figure 3, the clip portions iii are bent up into planes parallel to the planes of the blades 8, and spaced therefrom slightly less than the thickness of the blades.

As is evident from the drawings, both or the clips it] open to the same side of the saddle portion i6 and thus, when assembled in the tranverse channels 8 oi the block, as shown in Figures 1 and 2, the blades H of the terminal connectors, after being inserted vertically, are engaged by being swung down parallel.

One or the practical advantagesof the conhector block of the present invention is that, when the conductor terminals having the counterparts of the knife switch elements constituting parts of the connector block have been cross connected and/or interconnected through the block and the cover has been placed in positionon the block, all of the otherwise ulated conductive parts of the conductor terminals, two-way connectors, bridging switches, etc, are confined within the outer surfaces or the blocls, thus being protected from accidental contacts and short circuits. Only the insulated wire of the connections leading into the block is exposed beyond the insulation, 1 v

The invention further contemplates, in addition to the employment oi the novel interconnector thus iar described, a simple means for effecting interconnection and disconnection of successive inter-connector units in the block to take care of circuits where more than two wires are required to be interconnected. To facilitate such interconnection there is formed, integral with each clip 30 of the two-way connector, a laterally extending contact lug i. As shown in Figure 2, each contact lug i is formed by bending the blank strip l first to a position at substantially right angles to the side wall of the clip is and then back upon itsel: with a slight outward bend at 25 to provide a concave recess in the free end or the contact of substantially arcuate curvature of the same or slightly smaller radius as the rotatable bridging contact member 28. 'me bridging member 28 is formed at least in part of metal adapted to conduct current between the contact lugs i, it may be disconnected by being removed bodily, with or without substituting an insulating member as illustrated in Figure 11, or

it may be disconnected by rotating to move the metal part 22? away from the contacts l. in the latter case, the bridging'member 28 may be made of insulating material with a metallic insert posi-' tent, positionedfor example on the ends of the members 28 in recesses at the bottom of. block 2. The tops of members 28 are lrerfled or otherwise provided with means for turning them to the connecting or disconnecting positions and for visually distinguishing said positions.

When the terminal connectors 52 are all in place as desired, the cover 30 is applied as shown and latched in place by spring clips 32 on the end fittings 34 engaging in grooves 136. When the cover is thus in place everyconductive part is enclosed in the insulating block and moreover, since the terminal connectors M are fitted between the cover 30 and the bottoms oi channels 4. they are held positively against release irom engagement on the blades 8.

It will be observed also that the ends of the block 2 are like the corresponding parts of intermediate units, and that the entire block is made up of repetitive units each having the channels and recesses are described. Thus the device may be supplied in long strips and cut at any length. End fittings 3d slide onto the cut end of the block 2 and preferably an end plate 38 of insulation material is fitted over the end of the block 2 to assure complete insulation of the inter-connectors 5 from the end fitting 34.

The end fitting 311 may be of any suitable form to engage the end of the block 2 and advantageously is provided with means for securing in place the cover 3t. As shown, the end fitting is a sheet metal stamping formed with/a bottom plate having a hole to for reception or a screw or other fastening to hold the assembly in place on a panel or. other support, side channel portions 42 engaging ribs 64 on the bottom of theblo'ck 2 and thus securely holding block 2- when it is slid endwise into the fitting 35, and ears extending from the side portions 52, which are first turned inwardly at 66 to form end abutments limiting'tbezentry oi the block 3, and are then turned back into parallel position forming the ears 68 in which is mounted a pin 50 which constitutes an axle or pivot for the spring clip 32. The latter is provided near its end with a sharp told forming a likewise supplied in long lengths, the block and proper number of connections; and, with two or the standard end fittings to he slipped over the ends or the block, shownin Figure can be bled in a few minutes. I

From the foregoing description it will be seen that the improved two-way connector otthe present invention with its lateral contact extensions provides simple means not only for effecting interconnections through a connector block but for eflecting interconnections betweenthe two-way connectors within the block to obtain any desired multiple interconnections between conductors. It will be further seen that when the cross connections and interconnections have been made as shown in Figures 1 and 2, the terminal connectors ii are overlapped so that the interconnections are made within a minimum width, only insulated parts of the interconnected conductors are exposed. Moreover, when the cover lll has been put in position on the block 2, the terminal connectors are locked in the parallel position and thus are securely held against disengagement. There is thus no danger of accidental contacts being made which might cause current leakage or short circuits and" no danger o1 accidental disconnection which could render any circuit inoperative.

Although the two-way interconnector unit 5 of Figures 1 to 4 is particularly designed to attain the objects and advantages stated in a connector block. it is to be understood that interconnector units of other design can be used within the scope 01' my invention and that certain inventionsin the interconnector unit per so are useful and of advantage even apart from the cut to size and assema complete connector block, as

other elements of the connector block. As illustration of this there is shown in Figure 5 a modification of the connector unit and it is shown as used apart from the connector block.

The interconnector shown in Figure 5 consists of a simple strip in of sheet metal having blade portions la lying respectivel on spaced parallel planes with an offset portion lie between, and an integral projection Illa from the bottom or each blade portion near the offset portion "a. Each of these projections Illa is bent back over the face of its blade portion 8a but spaced therefrom a distance slightly less than its thickness. Thus the terminal connectors 12 are engaged by inserting their clips ll under the blades 8a while blades is are perpendicular and then swinging the blades to the parallel positions. the bottoms No of clips Illa serving as tulcrums for pushing the clips ll over the blades 8a and to limit the swinging or the terminals so as to assure the desired parallel positions and by engaging the clips its to prevent pulling apart of the terminals and interconnector by any pull on the wire. Thus it will be seen that the functioning and advantages of this form of interconnector are similar to those oi the interconnector 5 or Figures 1 through d.

The omission of the contact lugs I from the structure shown in Figure 5 and thus far described is optional-4: the interconnector were to be used in the block 2 such lugs would advantageously be provided; whereas, as shown, the intel-connector is used for connecting only two wires and instead of the fixed block 2 a simple tubularinsulating sheath is shown at 2a; so that the lugs I are not only unnecessary but would be undesirable.

Since the interconnector as shown permits overlapping of the terminal connectors on the wire, the connection shown in Figure 5 is of partrade name ticular advantage where space requirements limit the length or the terminal or' the space available for swinging the wires in making connection and disconnection, Likewise, this may 'be used ior connecting together terminals of different sizes. As shown in Figure 5, the lower right-hand connector-portion has been reduced in thickness by the stamping operation and is otherwise dimensioned to interilt with the next smaller size of terminal connector than that .which is engaged on the upper lei't-hand portion of the interconnector.

when the connection is made the insulating sheath 2a, which is advantageously a stiiiiy flexible tube or insulating materiahior example a plasticised vinyl chloride, vinyl acetate 'copolymer, such as is available commercially under the "Irvilite," is slipped over'one wire. The connection is then made as described above and with the terminals izvand lie and the interconnector is in parallel relation, as shown, the tubular sheath 2a is slipped over the connection, which it engages snugly and elastically and is thus held securely in place at once, locking the connection against accidental disengagement, insulating it against accidental contact, and protecting it mechanically against accidental injury.

The use of an insulating housing for such a connection is not the present invention, but is more particularly described and broad claimed in copending applications, Serial No. 55 ,326, died October 12, 1944 and Serial No. 562,985, filed November 11, 1944. Likewise the knife disconcase theinterconnector is a simple straight strip so that the planes or its blade portions 8b are not only parallel but actually coinciding; and the only departure from a simple blade is the clip portions lob bent up to opposite sides over the faces of the blades and at distances therefrom substantially equal to but slightly less than the thickness of the blades. v

The interconnector as shown in Figures 6 and 7 may, as already mentioned in connection with Figure 5. be adapted to connect terminals or the same size or may connect terminals of. different sizes. As shown, the interconnector is made with stock of thickness adapted to connect with the thinner or the two terminals and at the opposite end is punched to form a hump 6| and a corresponding recess on the other side such that a portion of the area engages the clip at its outside and the remaining area on its opposite side engages the blade. This arrangement aiso has the advantage of facilitating the entry or the blade under the clip, since the narrower stock readily enters between the clip and the blade or the counterpart connector and the border around the .in proper alignment and pressed against blades la, etc., by external means, such as the sheath essence is. In all cases. however, it is advantageous to have some abutment means to serve as a fulcrum, to limit the swinging of the terminals and to resist separation by longitudinal pull. some or all of these functions can be served by the offset II or. a, by the bottom of the channel 4 or of the tube 2a or by lugs at the bottom of the blades corresponding the parts 24, etc. In the case illustrated in Figures 6 and '7, as in the case of Figure 5, the omission of lugs 1 is optional, depending upon the use to which. the interconnector is to be put.

In Figures 8 to 11, inclusive, is shown a modified form of connector block similar to that of Figure 1. In this case, however, an end fitting is used which, as shown most clearly by Figure 10, can be stamped from a single piece of metal with full utilization. Portions "a at the center are bent out on the lines indicated, the part 36a. is then bent to vertical position, and side slide portions 42a are bent up first near the ends and then farther as indicated by broken lines on the drawing. The snap latch member 82a is then secured in place by bolt 50 and the end piece is complete.

As shown in Figure 11 the connection or insulation between the members is made by bolts,

' 28a of brass where adjacent members 5 are to be connected, and 28a having insulating sleeves 29. These bolts are secured'in the block in any convenient manner; as shown,. polygonal recesses are formed in the bottom of the block 2, which receive and lit nuts 85 into which bolts 28a and m" are threaded.

I claim:

1.-Atwo-way interconnector of the knife dis- 7 connect type comprising oppositely extending but obliquely offset integrally connected blades and associated clips, 'said obliquely offset blades lying in parallel planes and the clips associated therewith opening to the same side of the connecting body portion of the interconnecton.

2. A two-way, interconnector according to claim 1 in which integral projections extend laterally from each clip, and a housing is provided for said interconnector with a chamber for said interconnector and recesses communicating with said chamber in which said projections are respectively received.

3. A two-way interconnector according to claim lin which the connecting body portion of the interconnector comprises a saddle strip arranged obliquely integral parallel end portions and bent to bring the integral blades into parallel planes and. to form the integral clips 55 associated with the blades.

4.'A terminal block which comprises an insulating block having transverse channels therein and communicating centrally located longitudinal channels, interconnectors in said transverse channels each having oppositely extending blade portions lying in spaced parallel planes, an

integral centrally positioned saddle portion connecting and oifsetting'said blade portions and clip portions adjacent said saddle portion integrally connected to the blade portions respectively at the bottom edges thereof and extending over the face of the blade portion at a distance therefrom approximately the thickness of said blade portion and a contact lug extending laterally from each clip portion into said longitudinal channelin overlapping relation with the contact lug of an interconnector in an adjacent trans-v verse channel, and a bridging connector removably engaged between said adjacent contact lugs whereby removably to connect said adjacent interconnectors, and an insulating cover closin said channels, insulating said interconn'ectors and locking said terminal connectors against dis- 5 engagement from said interconnectors.

5. A terminal block as defined in claim 4 wherein end closures are fitted over the ends of the block and locking means on said end closures r m v ngage and hold said cover on said block.

6. A terminal block which comprises an insulating block having transverse channels therein and communicating centrally located longitudinal channels, interconnectors in saidtransverse 15 channels each having oppositely extending blade portions lying in spaced parallel planes, an integr-al centrally positioned saddle portion connecting and oifsetting said blade portions and clip portions adjacent said saddle portion integrally connectedto the blade portions respectively at the bottom edges thereof and extending over'the face of the blade portion at a distance therefrom approximately the thickness ofsald blade portionand a contact lug extending laterally from each .Zdclip portion into said longitudinal channel in overlapping relation with the contact lug of an interc-onnector in an adjacent transverse channel, and a bridging connector removably engaged between said adjacent-contact lugs whereby removably to connect said adjacent interconnectors.

7. An interconnector which comprises opposltely extending blade portions lying in spaced parallel planes and an integral saddle portion extending between and offsetting said blade portions centrally of the interconnector, whereby the clip and blade of a-knife disconnect type terminal may engage each of said blade portions while projecting portions of such terminal are accommodated by said offset, and clip portions ad- 40 jacent said offset adapted to engage the edges of such knife disconnect type terminals to limit free swinging of such terminals and to serve as fulcrums for lifting clip portions of such terminals into engagement on said blade portions and to limit longitudinal movement of such terminals when subjected to axial pull, and each clip portion having a part thereof extending over a part of the blade portion adjacent the offset and spaced from said blade portion a distance'approximately equal to. its thickness, and an integral lug on each clip pofrtion adapted for mounting the interconnector on a base.

8. An interconnector which comprises oppositely extending blade portions lying in spaced parallel planes and an integral oflsetting portion extending between said blade portions centrally of the interconnector, whereby the clip and blade of a knife disconnect type terminal may'engage each of said blade 'portions while projecting portions of such terminal are accommodated by said oilset, clip portions adjacent said offset adapted to engage the edges of such knife disconnect type terminals to limit free swinging of such terminals and to serve as fulcrums for lifting clip portions of such terminals into engagement on said blade portions and to limit longitudinal movement of such terminals when subjected to axial pull, and each clip portion having a part thereof extending over apart of the blade portion adjacent the off-- set and spaced from said blade portion a distance approximately equal to its thickness.

9. A terminal block-which comprises an insulating block having transverse channels therein. terconnectors in said tramverse channels each having oppositely extending blade portions lying 10. A knife disconnect type interconnector which comprises a blank defining a pair of blades extending in opposite directions from a midpoint, each blade being adapted to be received between the blade and clip of a knife disconnect type terminal such as is engageable with the interconnector blade by a swinging-wiping action with respect thereto, each interconnector blade having an integral tab portion spaced back from its outermost'end and bent out of the plane of the blade to form an abutment which limits swinging-wiping action of a terminal upon connection therewith, the tab portions of the two blades being spaced apart and being bent in opposite directions away from each other, a substantial portion of "the'edge of eachblade between the respective tab portion and the outermost end oi the blade lying closely adjacent the plane oithe tab-formed abutment.

11. A knife disconnect type interconnector which comprises a blank defining a pair of blades extending in opposite directions in the same plane from a midpoint, each blade being adapted to be received between the blade and clip of a knife dis connect type terminal such as is engageable with the interconnector blade by a swinging-wiping action with respect thereto, each interconnector blade having an integral tab portion spaced back from its outermost end and bent out of the plane of the blade to form an abutment which limits swinging-wiping action of a terminal upon connection therewith, the tab portions of the two blades being spaced apart and being bent in opposite directions away from each other, a substantial portion of the edge of each blade between the respective tab portion and the outermost end or the blade lying closely adjacent the plane of the tab-formed abutment. v

12. A knife disconnect type interconnector as claimed in claim 11 wherein at least one of the blades is provided with a projection to produce a localized area of increased blade thickness and in which said projection is located between one of the tabs and the end of the blank.

JAMES C. MACY.

REFERENCES CHILD The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,104,436 Menningen July 21, 1914 1,225,127 Heath May 8, 1917 1,750,246 Serrell Mar. 11, 1930 1,781,802 Bandoly Nov. 18,1930 1,784,697 Martin Dec. 9, 1930 2,281,221 Anderson Apr. 28, 1942 2,327,048 Joyce Aug. 17,1943 2,336,517

Wade Dec. 14, 1943 

